world of innovation

MicroPower 15 tThe best for micro injection molding

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PRECISE − EFFICIENT − ECONOMICALThe optimum for all types of micro parts

The advantages

» Reliable injection molding technology for shot weights from 0.05 to 4 g

» 2-step injection unit with screw plasticizing and plunger injection

» Energy-efficient, all-electric “Drive-on-Demand“ motor system

» Innovative 5-point toggle lever clamping unit

» User-friendly through new UNILOG B8 control system with integrated assistance systems

» Compact machine cell to accomodate a rotary table, robot, quality accurance system and conveyor belt inside the machine

» Matching integrated auxiliaries available (material dryer, material loader and temperature controller)

» Easy conversion into a clean room cell by adding a laminar flow unit

» Also as 2-component machine with second injection module and an adjusted rotary table available

The machine series

MicroPower standard: 1 clamping force size – 15 t

MicroPower MEDICAL: for clean room applications – 15 t

MicroPower COMBIMOULD: for multi-component injection molding – 15 t

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MicroPowerThe system highlights

» Clamping unit – all-electric – with optimal access The MicroPower clamping unit is a 2-platen system, in which the clamping force between the nozzle and the toggle lever side is transmitted by a U frame element. The moving platen is driven by an integrated, high-precision 5-point toggle lever. It moves the mold platen guided with high precision on linear bearings smoothly and with high dynamism.

» Plasticizing unit: best control of micro quantities Three injection unit sizes are available for MicroPower machines, with shot volumes ranging from 1.2 to 4 cm3. In all three of these aggregates, plasticizing is effected by a 14 mm 3-zone screw with a 20:1 L/D ratio. Injection takes place via a plunger either 5 or 8 mm in diameter, with injection pressure of up to 3000 bar and with an injection speed of up to 750 mm/s.

» Small platen drillings – optimal force transmission The small through holes of only 26 mm in both mold platens enable optimal clamping force transmission into the mold, thus providing ideal conditions for high precision and long service life of the molds.

» All-in-one production cell available on request The MicroPower system is totally modular. Therefore it can be extended into a complete production cell inside the standard machine frame by adding a WITTMANN SCARA robot, a rotary table, an optical parts inspec-tion system and a conveyor belt or glass container for finished parts.

» Clean room-compatible standard concept The standard machine frame is designed for easy cleaning. Without any structural alterations, it can be combined with a laminar flow unit, which supplies class 7 clean air according to ISO 14644-1 standard. Hygienic depositing of the finished parts is possible within the clean room cell strictly according to cavities in an 8-compartment depositing unit with glass containers.

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CLAMPING UNITFree mold space

» High precision The MicroPower clamping unit meets the most stringent require-ments for precision in movements and automation options. Its high standard of precision is achieved by guidance of the system platen on the clamping side and the mold carrier plate on the same linear bearings. The central positioning of the toggle lever inside the U frame clamping unit ensures symmetrical clamping force transmission into the mold.

» One machine size as standard – The clamping unit is available with 15 t clamping force. – The mold platens on the ejector side come in one uniform size of 240 x 248 mm as standard.

– The width of the fixed platen is 240 mm. – The maximum daylight between platens is 400 mm.

» Free access and flexible automation – Thanks to the U frame, the mold space remains free of tie-bars.

– Ample space is provided on both sides of the U frame for the installation of a rotary table (rotation diameter 443 or 466 mm), a parts handling robot and other auxiliaries for quality inspection and parts depositing.

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INJECTION UNITSpecially designed for micro parts

Anti-wear optionsIn addition to the high-quality standard finish, an extensive range of optional versions with extra anti-wear and/or anti-corrosion protection is available. Pre-defined option packages and a selection matrix facilitate the choice of the right version.

» Injection unit for extremely small quantities The MicroPower injection unit is equipped with a two-step plasticizing and injection unit. It is available in three sizes. What all three sizes have in common is their 14 mm plasticizing screw for processing standard-size granulates. The injection plunger comes in different sizes. They are available for shot volumes ranging from 1.2 to 4 cm3.

» One system for 3 shot volume levels The MicroPower plasticizing and injection aggregate is a 2-step unit. Step one is plasticizing with controlled back pressure. Step two is a separate plunger injection unit. The plunger of this ag-gregate functions simultaneously as a shut-off device to separate the melt channel of the plasticizing unit from the injection unit. Behind the injection plunger, an injection pressure sensor is located, which actively regulates the injection process and thus controls the precision and consistency of the molded parts.

The advantages of the MicroPower injection unit

» Low-stress metering at low pressure » System without check valve, therefore no damage to materials

through shear stress » FI-FO injection process (first in – first out) » Minimal pressure loss during injection » Extremely small melt cushion, consequently high temperature

stability of the shot volume » Shot weights below 50 mg possible » All standard granulates can be

processed.

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» Highly dynamic electric servo drive – Short rotary times – Parallel movements possible – Short cycle times

» Short changeover times – Optimal accessibility – Easy mold insertion and removal – Direct plug-in media connections for pneumatic systems/water

– Media supply via covered energy chain

» Great flexibility – Location of ejector possible in both injection stations

– Servo-electric ejector control for ultimate precision – Use as a 2x1-component machine also possible

» Sensitive and accurate The rotary plate moves virtually without friction on its linear bearings. The mold protection system is very finely adjustable and thus ensures optimal mold protection.

» Clean room-compatibility as standard – Smooth surface for fast cleaning – Encapsulated structure – Stainless steel cover

The all-electric rotary unit is laid out for running in the +/- 180° mode. The rotary table features high dynamism, flexibility, operational safety and mold protection packed into a minimum of space. The robust basic structure provides optimal clamping force trans-mission. In combination with the backlash-free toggle lever, it thus enables extremely energy-efficient operation of the machine. The direct drive situated behind the rotary table combines ultimate precision with high rotary speed.

CLAMPING UNIT − COMBIMOULD SOLUTIONFast rotary unit

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INJECTION UNIT − COMBIMOULD SOLUTIONDesigned for molding micro parts

» Parallel operation of the injection units possible In the MicroPower COMBIMOULD machine, both plasti-cizing and injection units can be operated parallel to each other. This equally applies to the ejectors, core pulls and air valves, which can be operated parallel to the clamping movement.

» H-H configuration Two parallel horizontal aggregates

– Both aggregates moveable individually – Effective thermal separation of the aggregates

» Flexible, modular, compact – Fast changeover between the injection units (PIM, LIM, thermoplastics)

– All standard granulates can be processed. – Part weights below 50 mg possible – Easy barrel change

» Ultimate prescision – 2-step screw-and-plunger system – Minimal injection times – Optimal injection pressure control combined with highly dynamic changeover to holding pressure.

2-component injection moldingA 2-component machine also is available by combining two injection aggregates placed next to each other and using a rotary table inside the clamping unit.

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clean room

rotary table

tempering device

camera monitoringstacking module

handling device

material dryer

material feeder

MicroPowerProduction cell “ex works”

The production cell concept is an “ex works” solution for MicroPower injection molding machines.

The advantages of the MicroPower production cell » Machine frame closed on all sides as standard.

Thus molding of the micro parts takes place in an isolated environment.

» The enclosed machine cell is designed to provide space for additional equipment modules inside the standard cell.

» The enclosed cell can be fitted with a clean room module. It consists of a suction filter and a ventilation unit for laminar air flow through the machine.

» Cost benefits, since all danger areas are covered and certified ex works.

» MicroPower clean room production cells are suitable for producing micro parts for medical technology, as well as the electronics, watch making and optical industries.

» CE mark included for every machine with an insider solution. No separate costs for individual examinations.

CE-certified by type examination

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MicroPowerThe option highlights

» Rotary table The rotary table enables use of 2 bottom mold halves to achieve shorter cycle times on the one hand, and on the other hand to implement insertion and removal processes. In the multi-component version, the rotary table serves to accommodate the two different mold halves.

» Silicone processing in micro dimensions For liquid silicone processing, for example in the production of medical components, a micro two-compo-nent material loader is available, including a blen-ding and metering system. With this equipment, the machine can be quickly converted from thermoplastics to LIM injection molding.

» High-precision coining (EXPERT-pvT-Coining) For the production of optical or micro-structured parts, a high-precision coining system is available as an optional equipment package. In this process, the coining pressure is controlled with high dynamism via the clamping stroke, depending on mold temperature or cavity pressure.

» HiQ control for hot runners With decreasing part size, the proportion of sprue in the shot volume increases, due to the nature of the system. Minimizing the proportion of sprue is given a high priority in WITTMANN BATTENFELD product development.

» WITTMANN auxiliaries in micro dimensions The optional WITTMANN 4.0 auxiliaries integration pa-ckage is the basis for “Plug & Produce” technology of WITTMANN BATTENFELD injection molding machines with auxiliary units from WITTMANN. WITTMANN auxiliaries specially developed for the MicroPower:

– TEMPRO plus D Micro 100/140/160 – DRYMAX Micro F2-15 compact + material loader – W8VS2 Vertical SCARA – W8VS4 Vertical SCARA

OPTIONENFlexible – proven – powerful

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UNILOG B8Complex matters simplified

UNILOG B8Highlights

» Operating logic with a high degree of self-explanation, similar to modern communication devices

» 2 major operating principles – Operating/movement functions via tactile keys – Process functions on touch screen (access via RFID, key card or key ring)

» Process visualization via 21.5" touch screen display (full HD), pivoting laterally

» New screen functions – Uniform layout for all WITTMANN appliances – Recognition of gestures (wiping and zooming by finger movements)

– Container function – split screen for sub-functions and programs

» Status visualization uniform signaling system across the entire WITTMANN Group. Headline on the screen with colored status bars and pop-up menus

» Operator assistance Extensive help library integrated

The UNILOG B8 machine control system is the WITTMANN BATTENFELD solution to facilitate the operation of complex processes for human operators. For this purpose, the integrated industrial PC has been equipped with an enlarged intuitive touch screen operator terminal. The visualization screen is the interface to the new Windows® 10 loT operating system, which offers extensive process control functions. Next to the pivo-table monitor screen, a connected panel/handset is mounted on the machine’s central console.

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“Single point entry” via router into the Industry 4.0

world

WITTMANN 4.0 systemWith WITTMANN 4.0, a machine and its robots and auxiliaries are transformed into a uniform technical or-ganism, which communicates externally via a specific IP address. A single point entry increases the cyber security significantly.

With its communication standard WITTMANN 4.0, the WITTMANN Group offers a uniform data transfer platform between injection molding machines and auxiliary equipment from WITTMANN. For an appliance exchange, the correct operating software is loaded automatically via an update function according to the “Plug & Produce” principle.

Connection of auxiliaries via WITTMANN 4.0

» WITTMANN robots with R9 control system – Operation of robots via the machine’s monitor screen – High-speed communication between machine and robot to synchronize movements

– Important machine movements can be set via the R9 robot control system

» WITTMANN TEMPRO plus D temperature controllers – Setting and control of temperatures via the machine’s control system possible

– All functions can be operated either on the unit or via the machine’s control system

Integration in MES systemThe integration of machines and complete production cells in an MES system is a prerequisite for an efficient and transparent produc-tion facility according to the Industry 4.0 concept. Depending on the customer’s requirements, small and medium-sized companies are offered a compact MES solution based on TEMI+. For large-scale and globally active companies, our cooperation partner is MPDV Microlab GmbH, a leading MES service provider. Due to the Windows® 10 IoT operating system, it is also possible to have selected status information from all connected machines on the production floor shown under SmartMonitoring on the display screen of every machine.

WITTMANN 4.0Barrier-free communication

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APPLICATION TECHNOLOGYOutstanding competence

» COMBIMOULD Two or more plastic materials in different colors or with different attributes can be combined into one part by upgrading the standard MicroPower with a second micro aggregate or by combining several machines into one production unit.

» Insert molding When individual parts such as plug contacts need to be insert-molded, an insert station on a rotary table outside the mold is avail-able for this purpose. A high-precision Scara handling robot and a metal parts feeding station can be integrated into the machine as additional modules.

» Clean room injection molding When medical components or electronic parts need to be manufactured in a particle-free environment, the MicroPower concept offers excellent conditions with its easy-to-clean mold environment and an optional clean air supply system.

» Reel-to-reel molding To produce electronic parts, punched struc-tures are fed through the clamping unit and insert-molded. The ample mold mounting space of the MicroPower offers optimal condi-tions for this process.

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» PIM (CIM/MIM) − Powder Injection Molding Powder injection molding (PIM) is a manufac-turing process for series production of parts made of metallic or ceramic materials. PIM is the ideal process to make complex, functional components with stringent material require-ments in large quantities.

» Microstructures The quality of the plastic melt generated gen-tly and at a constant temperature inside the MicroPower injection unit is particularly suited for high-precision reproduction of micro structures inside the mold, from sensor structures to Fresnel lenses or copy protection holograms.

» LIM – Liquid Injection Molding LIM designates the injection molding process for making elastic parts from 2-component liquid silicone rubber (LSR). LIM micro parts are used for optical and medical applications.

» High-precision micro parts In addition to standard plastics processing, the MicroPower injection unit is an ideal choice for manufacturing high-precision parts from engineering plastics such as POM, PEEK or PSU.

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STANDARD

Base machinePaint RAL 7047 tele grey 4/RAL 5002 ultramarine blueRectangular main beam on one-piece base frameBuilt-in control cabinetPart transp. on operator side, or parallel to machine axis

Drillings for auxiliary equipment – like robot, camera, etc. – operator sided on rectangular main beam

Clamping unitClamping system: 5-point toggle with servo-electric direct driveServo-electric mold height adjustmentClamping and opening forces for mold safety system adjustable

Mold safety program with envelope curves monitoring for optimal mold cover

Precise platen parallelism with low-maintenance moving platen supportPlaten drillings metrical as per EUROMAPClamping force displayed on screenClamping force monitoring incl. display via screenServo-electric ejectorMechanical ejector coupleCooling hole in the mold mounting platen

Injection unitServo-closed loop controlIncreased injection performance

Screw drive by 3-phase servo motor, screw speed continuously adjust-able via screen

Barrel, screw, distributor block and injection nozzle in hot-work tool steel, injection piston TIN coated

Thermocouple failure monitorPlug-in ceramic heater bandsOpen nozzleQuick removal for injection nozzle and cylinderHopper of V2A stainless steel can be shut and emptiedLinear bearings for the injection unitSelectable barrel stand-by temperature Decompression before and/or after meteringPhysical units – bar, ccm, mm/s etc.Screw protectionAuxiliary screw speed indicationLinear interpolation of holding pressure set valuesBar chart for barrel temperature with set value and actual value displaySelectable injection pressure limitation

Changeover from injection to holding pressure depending on stroke, time and pressure

Safety gateMaintenance-free safety gate locked by electromagnetSafety gate with electric monitoring according to CE standardSafety gate on the rear side

Cooling and conditioningWatercooling with open cooling systemFeeding zone with controlled cooling system

Additional equipmentOperating instructionsUser manual

ElectricsOperating voltage 230/400 V-3PH, 50 HzCommon voltage supply for drive and heatSeparate voltage supply for drive and heat USA/CDNUSB – 1 x operating unit1 Ethernet interface (switch cabinet)Printer via USB connection or networkSignal lamp at the machine

Control systemControl system UNILOG B8 – 21,5‘‘ multi-touch screen (full HD)Software for operating hours counterClosing/opening – 5 profile steps Ejection forward/back – 3 profile steps Injection/holding pressure – 10 profile stepsInjection parallel to clamp force build-upScrew speed/back pressure – 6 profile stepsParts counter with good/bad part evaluationPurging programStroke zero offset settingsStart-up programAdjustable injection pressure limitation

Switchover to holding press. MASTER/SLAVE by injection time, screw stroke/injection vol. and injection pressure

Self-teaching temperature controllerDisplay of temperature inside electrical cabinetSeven-day timer

Access authorization via USB interface, password system and RFID authorization system

Freely configurable status barPhysical, process-related unitsEnergy consumption monitoring for motors and heatingAutomatic dimmingLogbook with filter function User programming system (APS)Cycle time analysisEnergy measurement displayedFreely configurable screen pages „user page“Notepad functionHardcopy functionInternal data storage via USB connection or networkOnline language selectionOnline selection of imperial or metric unitsOperator manual incl. hydr., mech. and el. schedules onlineTime monitoring

BASIC Quality Monitoring (1 freely configurable network connection, quality table with 1000 storage depth, events protocol (logbook) for 1000 events, actual value graphics with 5 curves, 1 envelope curves monitoring)

Injection integral supervisionMetering integral supervisionAlarm message via EmailSmartEdit – sequence editor

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OPTIONS

Clamping unitServo electric rotary tableMechanical mold safety mechanismSPI bolt patternEjector platen safety device as per EUROMAP 13Parts chute for separation of good/bad partsNickel plated platen in lieu of standardAir valve, action initiated (ON) and timer (OFF)Non-standard layout of fastening bores in clamping/nozzle platenTurning-out device with servo motor, installed on ejector plate

Injection unitGrooves in the feeding zone of barrel for improved feedingHigh temperature heaterbands up to 450 °C Barrel insulation

Enter block with additional connection for nitrogen supply in lieu of standard

Wear and corrosion resistant injection unit AK+Equipment package for liquid siliconeEquipment package for PIM (MIM/CIM)Equipment package for technical plastics (PC, PMMA, ABS)Equipment package for bioresorbable materialsScrew in special geometryConversion kit injection unit reduction to size 3 in AK+

Vacuum package: vacuum pump incl. interface, vacuum valve, vacuum sensor

Material hopper in DURAN glas design, 0.6 litres in volumeConnecting flange for customer-supplied hopper drier or drying unitEquipment packages available in lieu of standard and/or in addition

Safety gatePneumatic safety gate at the operator sideInitiation of the next cycle by closing safety gate in semi-auto operationFront side safety system for manual part removal

PneumaticPneumatic maintenance unit incl. pressure regulationPneumatic core pullers incl. pressure regulatorAdditional compressed-air controller

Cooling and conditioningWatercooling with closed cooling systemHosting of cooling circuits on the fixed platen of the moving platen Integrated WITTMANN temperating units and dryerCooling circuits 2x additionally without shut-off valve

Granulat/dryer/feederIntegrated WITTMANN dryer/dew point sensorIntegrated WITTMANN feeder

Robot/handling unitW8VS2 WITTMANN Vertical Scara Robot with 3 servo axisW8VS4 WITTMANN Vertical Scara Robot with 4 servo axisTeachbox R8.2/R9Additional valveAdditional vacuum circuit (Venturi)Additional vacuum circuit (Venturi with blow-off function)I/O expansion control cabinet (8I/8O)Interface for COGNEX cameraAdapter for gripper plate (EOAT) with crash sensorConveyor belt

ElectricsTemperature control zone for hot runnerSpecial voltageControl cabinet coolerInterface for handling equipmentTemperature control interface digital, serial 20 mA TTY protocolCAN-Bus-interface for mold conditioner as per EUROMAP 66-2 Interface for WITTMANN dryer integratedInterface for WITTMANN temperating units integratedInterface for robots as per EUROMAP 67Interface for robots as per EUROMAP 67 with add. signals for rotary tableInterface for conveyor belt and dosing unitInterface for full integration of robot incl. Ethernet switchHost computer interface/PDA (EUROMAP 63) Relays contact parallel to plasticizing Kistler module for cavity pressure dependent switchover BNC connectors for injection process analysisMachine fault (potential-free contact) Part inlay monitoring via vacuumSignal tower with acustic elementCEE socket 16 A

Protection of the socket circuits via residual-current-operating circuit breaker with 30 mA conventional tripping current

Additional emergency-stop button, mounted on the rear of the machineInterface evacuation with software (incl. vacuum valves for rotary table)Interface for freely configurable mold monitoring

Control systemEnergy consumption analysisSwitch over to holding pressure by cavity or melt pressureSwitch over to holding pressure by external signalInjection compression and venting sequencesSecond injection data setting for automatic start upHiQ Cushion® − melt cushion controlHiQ Flow® − injection integral controlHiQ Melt − monitoring of material qualityInjection compression program/Extended injection compression programGate start special programSpecial program according to customer specificationUser specific limiting input value systemProgram in US dimensionsRJG eDart interface

EXPERT Quality Monitoring (4 freely configurable network connections, quality table with 10000 storage depth, events protocol (logbook) for 10000 events, actual value graphic with 16 curves, 4 envelope curves monitoring, SPC charts, trend diagrams)

Add. screen text not according to EU (max. 2 languages in add. to German)

Second injection parameter record for lower mold allocation or injection parameter change-over during start-up phase

Variotherm processing package

Additional euipmentSpecial paint and/or touch-up paintTool kitLevelling padsLighting in mold spaceDistance blocks 100 mm for leveling mountsSpare parts packageSprue-cut-off-appliance with air nozzleClean room boxVisual quality inspectionIonization8-fold parts depositing

WITTMANN BATTENFELD GmbH

Wiener Neustädter Strasse 81

2542 Kottingbrunn | Austria

Tel.: +43 2252 404-0

info@wittmann-group.com

www.wittmann-group.comM

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